During the transmission clutch fill calibration (submode 40), error codes (EXX) can occur. The error codes will appear in the display area of the Caterpillar Monitoring System. The error codes will appear if a problem occurs during the calibration or if there is a problem with the results of the calibration.
| Error Codes for the Calibration of the Transmission Clutch Fill | |
| E01 | The Clutch Solenoid or the Speed Sensor has an Active Fault. |
| E04 | The Transmission Direction Control Switch (If Equipped) is Not in the Neutral Position. |
| The Transmission Direction and Speed Control Lever (If Equipped) is Not in the Neutral Position. | |
| E05 | The Temperature of the Transmission Oil is Below the Fault Threshold. ( 40°C (104°F)) |
| E06 | The Engine Speed is Below the Fault Threshold of 1800 rpm. |
| E07 | The Parking Brake Is Not Engaged. |
| E09 | Machine Speed Is Not Zero. |
| E11 | Calibration of the Transmission Clutch Engagement Pressure Is Not Completed. |
| E21 | Number 1 Clutch at a Limit Reverse |
| E22 | Number 2 Clutch at a Limit Forward |
| E23 | Number 3 Clutch at a Limit Fourth Speed |
| E24 | Number 4 Clutch at a Limit Third Speed |
| E25 | Number 5 Clutch at a Limit Second Speed |
| E26 | Number 6 Clutch at a Limit First Speed |
The calibration software may need to adjust one of the parameters beyond the limit of the design specification. In this case, error codes E21, E22, E23, E24, E25, or E26 will appear in the display area after the calibration procedure is complete. The software will select the best values, but the error code indicates that an error exists in either the conditions for calibration or the transmission system. If error codes E21 through E26 are displayed, check the following conditions for the source of the error:
- Make sure that the transmission oil and the transmission components are fully warmed in order to run the calibration.
- Make sure that the transmission clutch modulating valves are correctly torqued. (Make sure that the valves are cool when the valves are torqued.)
- Worn seals are causing leakage.
- The clutch is worn beyond the allowable range.
- The transmission clutch modulating valve is damaged.
- A new transmission clutch modulating valve was not energized sufficiently.
 | |
| Illustration 1 | g00777672 |
Transmission clutch modulating valves (1) Number 1 transmission clutch modulating valve (Reverse). (2) Number 2 transmission clutch modulating valve (Forward). (3) Number 3 transmission clutch modulating valve (Fourth speed). (4) Number 4 transmission clutch modulating valve (Third speed). (5) Number 5 transmission clutch modulating valve (Second speed). (6) Number 6 transmission clutch modulating valve (First speed). | |
Note: If a new transmission clutch modulating valve was installed, shift the transmission for at least 12 times into a speed or a direction that uses the transmission clutch modulating valve. Refer to Illustration 1 in order to identify the transmission clutch modulating valve and the corresponding clutch. Allow sufficient time for the corresponding clutch to be fully pressurized.
During the transmission clutch fill calibration, error codes (EXX) can occur. The error codes will appear in the display area of the Caterpillar Monitoring System. The error codes will appear if a problem occurs during the calibration or if there is a problem with the results of the calibration. If there are no problems or if the problems are fixed, run the calibration (submode 40) again.
Calibration Procedure
 |
Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. |
 |
| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Park the machine on a smooth, level surface.
- Shift transmission direction and speed control lever (7) (if equipped) to the NEUTRAL position and in any speed position. Shift transmission direction control switch (8) (if equipped) to the NEUTRAL position.
 | |
| Illustration 2 | g00777670 |
Transmission Direction and Speed Control Lever | |
 | |
| Illustration 3 | g00777671 |
Transmission Direction Control Switch | |
- Lower the bucket and/or the attachment to ground.
- Engage the parking brake.
- Place blocks in front of the wheels and behind the wheels.
- Install the steering frame lock.
- Allow only authorized personnel on the machine. Keep unauthorized personnel off the machine and in clear sight of the operator.
Note: The steps of this procedure must be performed exactly, as described below. This procedure may terminate if any unknown functions or any unexpected functions are activated. This procedure may terminate if a fault (CID FMI) is present. Do not move any switch positions, any levers or any pedals unless you are instructed differently.
| Required Tools | ||
| Part Number | Description | Quantity |
| 4C-8195 | Control Service Tool | 1 |
Note: If a new transmission clutch modulating valve was installed, shift the transmission for at least 12 times into a speed or a direction that uses the transmission clutch modulating valve. Refer to Illustration 1 in order to identify the transmission clutch modulating valve and the corresponding clutch. Allow sufficient time for the corresponding clutch to be fully pressurized.
- The calibration of the transmission clutch engagement pressure (submode 31 through submode 36) should be performed prior to the calibration of the transmission clutch fill (submode 40).
Reference: For more information on the calibration of the transmission clutch engagement pressure (submode 31 through submode 36), refer to Testing and Adjusting, "Engagement Pressure for the Transmission Clutch - Calibrate" for the machine that is being tested.
- Shift transmission direction and speed control lever (7) (if equipped) to the NEUTRAL position. Shift transmission direction control switch (8) (if equipped) to the NEUTRAL position.
- Engage the parking brake.
- Increase the engine speed to high idle.
- Warm the transmission oil to at least 68°C (154°F).
- Use the 4C-8195 Control Service Tool to enter Transmission Calibration Mode (8) by using the "MODE" switch. Then scroll to submode 40 by using the "SCROLL" switch. Enter submode 40 .
- If all the conditions are correct for calibration, "0" will move across the display area of the Caterpillar Monitoring System.
Note: If all the conditions are not correct for calibration, "0" will not move across the display area. Instead, an error code (EXX) will appear. The calibration will not run until all necessary conditions are met. Correct the error code and perform these procedures again.
- When all conditions are met and "0" is shown in the display area, shift transmission direction and speed control lever (7) (if equipped) to the FORWARD position. When all conditions are met and "0" is shown in the display area, shift transmission direction control switch (8) (if equipped) to the FORWARD position. This begins the actual transmission clutch fill calibration.
- The number in the display area changes and the number of the clutch (1 to 6) that is being calibrated is now shown. The calibration procedure automatically advances to the next clutch.
Note: During the calibration of the transmission clutch fill, many transmission clutch fills are occurring. Remain seated. There will be some vibration and noise as the clutches are being calibrated. If any of the conditions for calibration are violated during the calibration, the calibration will be stopped and the corresponding error code (EXX) will be shown in the display area. Correct the error code and perform these procedures again.
- When the calibration of all the clutches is successfully completed, "---" will be shown in the display area. An error code (EXX) may also be shown. This indicates a problem with the calibration. The adjustments may not have been completed.
- Shift transmission direction and speed control lever (7) (if equipped) to the NEUTRAL position. Shift transmission direction control switch (8) (if equipped) to the NEUTRAL position. This completes the transmission clutch fill calibration.
- To exit submode 40, scroll to the next submode by using the "SCROLL" switch or exit the Transmission Calibration Mode by using the "MODE" switch.
- Operate the machine in order to check the quality of transmission shift.